How to Cut 45-Degree Angles on a Horizontal Band Saw Without Readjusting Your Saw
If you run a horizontal band saw, you know the drill: a project calls for a few 45-degree cuts, so you loosen the bolts, swing the saw, fine-tune the angle plates, make your cuts — then set it all back square and dial it in again. Every swing is time lost, and on a lot of saws those adjusters are the first thing to wear out.
The fix: leave the saw square
Instead of moving the saw, we built a clamp-on 45-degree jig. Your main plate stays straight and square; when you need a 45, you clamp the jig on and cut. When you're done, pull it off — your saw never moved, so there's nothing to re-square.
The result is quick, repeatable 45-degree cuts with no bolt-loosening and no fine-tuning between angle and square work.
The angle iron trick
The jig ships with a 1.36" x 1.36" x 5" precision spacer with radiused edges that fits snugly inside 1.5" angle iron. Here's why that matters: when you miter angle iron, you normally cut one side at 45, then re-set your setup to cut the other side. With the spacer, you just flip the angle iron over, drop the spacer in, and clamp it securely for the second cut. Same setup, both sides. This one trick has saved a lot of time in our shop.
The current version also has reinforcement in the middle that doubles as a holder for the spacer, so it doesn't wander off between jobs.
Fair warning
This is an unauthorized add-on for your saw — use it at your own risk. It's earned its keep in our own shop, but you know your equipment and your comfort level.
Need a different angle?
The jig is designed and made in-house at our Kansas City shop. If you need a different angle, a different color, or something custom for your saw, send us a message — custom work is what we do.